1. The function of pumping systems 2. Common pump types 3. The basic theory of operation of centrifugal pumps 4. The basic theory of operation of diaphragm pumps 5. The major components of a pumping system, including the building and piping system 6. Terms used to identify common pumps and their components 7. The weight of a cubic foot of water 8. How to convert between cubic feet and gallons 9. The difference between force and pressure and what impacts them 10. How to convert between psi and feet of head 11. The difference between psi and feet of head 12. The relationship between fow in cubic feet per second and gallons per minute 13. The terms used to describe static and dynamic hydraulic conditions 14. Headloss and its causes 15. The terms used to describe pumping conditions Introduction to Pumping Systems Amperage Axial Flow Pumps Can Turbine Pumps Cavitation Centrifugal Force Centrifugal Pump Close-coupled Pumps Concentric Reducer Displacement Pumps Dynamic Pumps Eccentric Reducer End Suction Centrifugal Pumps Energy Foot Valve Force Frame-mounted Pumps Headloss Horsepower Impeller Inertia Line Shaft Turbine Pumps Mechanical Seal Packing Pressure Pump Bowl Seal Water Shroud Split Case Pumps Static Stuffng Box Submersible Turbine Pumps Suction Head Suction Lift Total Dynamic Head Velocity Head Vertical Turbine Pumps Volute Key Words 198 Introduction to Pumping Systems Chapter 6 2 Displacement Pumps Pumps in which the energy is added to the water periodically and the water is contained in a set volume. Lesson Content This lesson provides an overview of the major pumping-related components found in small water systems. The lesson focuses on descriptions of components, common names, and general function. Functions Pumping stations in small communities are used for the following purposes: Remove water from a source, such as a river, lake, reservoir, well, spring, or muskeg pond. Move water from the treatment plant to the distribution system or reservoir. Circulate water through a distribution system. Maintain pressure in the distribution system. Circulate glycol through a heat exchanger or heating loop. Pump chemicals into the system. Major Components A pump station is composed of four sets of components: The building The hydraulic system: the pump and related piping The electrical system: the motor and its related components The control system: pressure, fow, and level switches Pump Station Buildings Introduction In medium-to-large facilities, pumping stations are usually separate buildings. In small systems, while they can be separate buildings, they are normally associated with the treatment plant, watering point, or other buildings. Basic Consideration Regardless of the design, most pumping station buildings are designed with the door opening out to allow access should there be a broken water line in the building. In addition, the buildings should be vandal-resistant, well-heated in the winter, and properly vented in the summer. Hydraulic System Pump Types The pumps used in small water systems can be divided into two general categories. The basic difference between the two types is their response to changes in discharge pressure. Dynamic pumps 1 Dynamic pumps are used in conditions where high volumes are required and a change in fow is not a problem. As the discharge pressure on a dynamic pump is increased, the quantity of water pumped is reduced. One type of dynamic pump, centrifugal pumps, are the most com- mon pump used in water systems. Dynamic pumps can be operated for short periods of time with the discharge valve closed. Displacement pumps 2 Displacement pumps are used in conditions where relatively small, but precise, volumes are required. Displacement pumps will Pump Stations 1 Dynamic Pumps Pumps in which the energy is added to the water continuously and the water is not contained in a set volume. 199 Chapter 6 Introduction to Pumping Systems not change their volume with a change in discharge pressure. Displacement pumps are also called positive displacement pumps. The most common posi- tive displacement pump is the diaphragm pump used to pump chlorine and fuoride solutions. Operating a displacement pump with the discharge valve closed will damage the pump. Pumps Dynamic Pumps Displacement Pumps End Suction Centrifugal Split Case Vertical Turbines Special Effect Pumps Jet pumps Regenerative turbines Vortex pumps Reciprocating Piston Diaphragm Rotary Peristaltic Progressive cavity Multiple gear - lobe Energy Input Device A pump is a device that puts energy 3 into the water. This energy can be expressed in two ways: an increase in pressure or an increase in fow. Centrifugal Pumps Energy Input If you were to cut a section out of the top of a pipe and use a canoe paddle to move the water, you would have a pump. It would not be very effcient, but you would be inputting energy into the water. If you reshaped the paddle into an impeller 4 , you would be able to place more energy into the water. The energy would be transferred from the impeller to the water due to the friction between the impeller and the water. However, water would splash out onto the foor. This is because centrifugal force 5
causes the water to fy outward away from the impeller. The Pump Case If you surrounded the impeller with a case, you could control the water and obtain a more effcient energy transfer. The case that you would use is volute (spiral-shaped). Volute 6 is a geometrical shape, like a circle or a square. For example, a snail shell is volute-shaped. The shape of the case helps to determine the direction of rotation of the pump. 3 Energy The ability to do work. Energy can exist in several different forms, such as heat, light, mechanical, electrical, or chemical. Energy can neither be created nor destroyed, but can be transferred from one form to another. Energy exists in one of two states: potential or kinetic. 4 Impeller A rotating set of vanes designed to impart rotation to a mass of uid. 5 Centrifugal force The force that when a ball is whirled on a string, pulls the ball outward. On a centrifugal pump, it is the force that throws water from the spinning impeller. Centrifugal Pumps - Pumping Theory d i s c h a r g e suction IMPELLER EYE IMPELLER VOLUTE POWER 6 Volute The spiral-shaped casing sur- rounding a pump impeller that collects the liquid discharged by the impeller. 200 Introduction to Pumping Systems Chapter 6 Pump Rotation The direction of rotation can be determined when looking into the suction side of the volute case. For example, in the case below, the direction of rotation is counter- clockwise. IMPELLER ROTATION ELECTRICAL ENERGY PRESSURE HEAD AND VELOCITY HEAD VELOCITY HEAD MECHANICAL ENERGY In summary, there are two theories that explain how a centrifugal pump 7 works: Energy transfer the transfer of energy from the shaft to the impeller and from the impeller to the water. Centrifugal force the force used to throw the water from the impeller. Centrifugal Pumps Confguration Three Different Confgurations Centrifugal pumps can be divided into one of three classifcations based on their con- fguration: end suction centrifugal 8 , split case 9 , and vertical turbines 10 . End suction centrifugal Split case Vertical turbine 8 End Suction Centrifugal Pumps The most common style of centrifugal pump. The center of the suction line is centered on the impeller eye. End suction centrifugal pumps are further classied as either frame-mounted or close-coupled. 9 Split Case Pumps A centrifugal pump designed so that the volute case is split horizontally. The case divides on a plane that cuts though the eye of the impeller. 10 Vertical Turbine Pumps A clas- sication of centrifugal pumps that are primarily mounted with a vertical shaft; the motor is commonly mounted above the pump. Vertical turbine pumps are either mixed or axial ow devices. 7 Centrifugal Pump A pump consist- ing of an impeller xed on a rotating shaft and enclosed in a casing, and hav- ing an inlet and discharge connection. The rotating impeller creates pressure in the liquid by the velocity derived from centrifugal force. 201 Chapter 6 Introduction to Pumping Systems End Suction Centrifugal - Types The end suction centrifugal pump is the most common centrifugal pump and the one we have in mind when we think about centrifugal pumps. There are two types of end suction pumps: Close-coupled 11 A close-coupled pump has only one shaft and one set of bearings: the motor shaft and bearings. The pump impeller is placed directly onto the motor shaft. Close-coupled pumps require less space and are less expensive than frame-mounted pumps. VOLUTE STUFFING BOX MOTOR Frame-mounted 12 A frame-mounted pump has a shaft and bearings sepa- rate from the motor. A coupling is required to get the energy from the motor to the pump. VOLUTE STUFFING BOX MOTOR FRAME For safety purposes, couplings should have guards installed. Split Case Pumps Split case pumps are unique. The case has a row of bolts that allow half of the case to be removed, providing access to the entire rotating assembly for inspection or re- moval. These pumps are normally found as fre service pumps and circulation pumps in medium-to-large communities. The circulation pumps in Nome and Fairbanks are split case pumps. Vertical Turbines There are four styles of vertical turbines: line shaft 13 , axial fow 14 , can turbine 15
and the submersible turbine 16 . The vertical turbine and the submersible turbine are found in rural communities in Alaska. The primary difference between the vertical turbine and the submersible turbine is the position of the motor. The pumping assem- bly is the same. Submersible turbine pumps in Alaska can range from 5 gpm to 100 gpm or more.
13 Line Shaft Turbine Pumps A type of vertical turbine. In this type of vertical turbine, the motor is mounted above the ground, and the pump unit is mounted below the water surface. A column extends from the pump to a discharge head found just below the motor. A shaft extends on a straight line from the center of the motor to the pump. The pump may be mounted a few feet to several hundred feet away from the motor. 14 Axial Flow Pumps A type of vertical turbine that uses a propeller instead of an impeller. In axial ow pumps, the energy is transferred into the water so that the direction of the ow is directly up the shaft. 15 Can Turbine Pumps A type of line shaft turbine. The pump assembly is mounted inside of a sealed can. The inlet is mounted opposite the outlet on the discharge head. The can must always be under pressure. 16 Submersible Turbine Pumps A style of vertical turbine pump in which the entire pump assembly and motor are submersed in the water. The motor is commonly mounted below the pump. 12 Frame-mounted Pumps End suction centrifugal pumps designed so that the pump bearings and pump shaft are independent of the motor. This type of pump requires a coupling between the pump and the motor in order to transfer energy from the mo- tor to the pump. 11 Close-coupled Pumps End suction centrifugal pumps in which the pump shaft and motor shaft are the same. The pump bearings and motor bear- ings are also the same. The impeller is attached directly onto the end of the motor shaft. 202 Introduction to Pumping Systems Chapter 6 BEARING SUCTION BELL PUMP BOWL PROPELLER DISCHARGE PUMP UNIT INLET HOLLOW SHAFT MOTOR SUCTION VESSEL OR "CAN" DRIVING SHAFT
Axial fow turbine Can turbine Submersible turbine End suction Centrifugal and Split Case Components Shaft and Bearings The shaft is used to transfer energy from the motor to the impeller. The most com- mon shaft materials are high carbon steel and stainless steel. Each shaft is supported by bearings that support loads along the shaft, called thrust loads, and loads at right angles to the shaft, called radial loads. The bearings may or may not be part of the motor. Impellers The energy is transferred from the shaft to the impeller and from the impeller to the water. There are three types of impellers, based on the number of shrouds 17 : Closed impeller When an impeller has a shroud in the front and in the back. Semi-open impeller When there is only a shroud in the back of the impeller. Open impeller When there are no shrouds. The impeller type is selected by the pump manufacturer to meet specifc conditions. Closed Semi-open Open 17 Shroud The front and/or back of an impeller. 203 Chapter 6 Introduction to Pumping Systems Wear Rings With closed impellers, the impeller fts very close to the case. As a result, the case is worn by material passing from the high-pressure side to the low-pressure side of the impeller. To protect the case, brass or stainless steel wear rings are inserted into the case. Volute Case Around the impeller is the volute case. The volute case gathers the water thrown from the impeller and directs it in a single direction. CLOCKWISE COUNTER CLOCKWISE Backing Plate Behind the volute case is the backing plate. The backing plate seals the back of the volute case area. Stuffng Box Attached to, and sometimes part of, the backing plate is the stuffng box 18 . The stuff- ing box is where material that controls the leakage of water from around the shaft is placed. The material placed in the stuffng box is either packing 19 or a mechanical seal 20 . Packing/Mechanical Seals Packing and mechanical seals serve the same purpose: they control leakage through the stuffng box. Packing is composed of some type of fber, like cotton, and some type of lubricant, like graphite or Tefon TM . A mechanical seal is composed of two fnely machined surfaces, one hard and one soft, that prevent water from passing. When installing packing, joints should be staggered. Packing Gland In order to control leakage with packing, pressure must be placed on the packing. This pressure is applied by the packing gland, two pieces of metal at the back of the stuffng box. Lantern Ring It is often desirable to lubricate and cool the packing with external water or oil. When water is used, it is called seal water 21 or fush water. The seal water is distributed into the stuffng box through the lantern ring, which is commonly a brass ring with holes that allow the water to easily pass. Shaft Sleeve To protect the shaft from damage due to the packing, a shaft sleeve can be installed. A shaft sleeve is a brass or stainless steel sleeve that fts tightly over the shaft. 18 Stufng Box That portion of the pump that houses the packing or me- chanical seal. Usually referred to as the dry portion of the pump. The stufng box is located in back of the impeller and around the shaft. 19 Packing Material made of woven animal, plant, mineral, or metal ber and some type of lubricant, placed in rings around the shaft of a pump and used to control the leakage from the stufng box. 20 Mechanical Seal A mechanical device used to control leakage from the stufng box of a pump and usu- ally made of two at surfaces, one of which rotates on the shaft. The two at surfaces are of such close toler- ances as to prevent the passage of water between them. 21 Seal Water The water supplied to the stufng box to lubricate and ush the packing or the mechanical seal. 204 Introduction to Pumping Systems Chapter 6 E L E C T R I C
M O T O R
O R
F R A M E STUFFING BOX BRAIDED FABRIC PLASTIC METAL FOIL Stuffng box Packing I m p e l l e r Spring Seal Gland Rotating Element Secondary Seals Retainer Stationary Element Mechanical seal shaft sleeve threaded to shaft impeller end Shaft sleeve threaded to shaft Review 1. List the two major categories of pumps. 2. How is energy transferred from the impeller of a centrifugal pump to the water? 3. The energy placed into the water by a pump can be expressed as an increase in ______________ and an increase in ______________. 205 Chapter 6 Introduction to Pumping Systems End suction Centrifugal and Split Case Piping Suction Conditions End suction and split case pumps can be installed in suction lift 22 or suction head 23 conditions. (See Hydraulics section for a more detailed explanation.) The piping system associated with the pump varies slightly depending on the suction conditions. Since the suction lift condition is the most diffcult, it is used in the following de- scription.
Suction lift Suction head Suction Piping Most pumps in a suction lift condition require a foot valve 24 on the end of the suction line to prevent the pump from losing prime. Most foot valves are large globe valves. The suction piping is usually designed one pipe size larger than the inlet of the pump with smooth piping material and fttings. Isolation valves on the suction side of a pump should only be gate or ball valves. Butterfy valves cause high headloss 25 . As the piping reaches the pump, it is reduced to meet the pump connection using an ec- centric reducer 26 . The eccentric reducer prevents air accumulation in the piping. CONCENTRIC REDUCER CHECK VALVE SEAL WATER ECCENTRIC REDUCER FOOT VALVE 22 Suction Lift A pumping condition where the eye of the impeller of the pump is above the surface of the wa- ter from which the pump is pumping. 23 Suction Head A pumping condition where the eye of the impeller of the pump is below the surface of the wa- ter from which the pump is pumping. 24 Foot Valve A one-way valve placed at the entrance of a suction line that is opened by the ow of water. The purpose of the valve is to prevent reverse ow. 25 Headloss The loss of energy as a result of friction, commonly expressed in feet. The loss is actually a transfer to heat. 26 Eccentric Reducer A device used to connect a large pipe to a smaller pipe so that one edge of both pipes is aligned. 206 Introduction to Pumping Systems Chapter 6 Discharge Piping The discharge side of a pump usually starts with a concentric reducer 27 , which takes the pipe up to one pipe size larger than the pump discharge. An isolation valve, pref- erably a gate or ball valve, is normally installed on the discharge. To reduce repair costs, a fange-by-fange spool or expansion joint is placed between the isolation valve and the pump. Controlling Flow and Pressure Ball valves and wide body globe valves are used to control fow and pressure from a pump as well as reduce water hammer during shutdown. Check Valve To prevent the fow of water back through the pump, a check valve is often placed in the discharge line. If there is a fow or pressure control valve, then a check valve is not necessary. Gauges To evaluate pump operating conditions, pressure gauges are placed on the suction and discharge sides of a pump. Ball valves are installed at the base of the gauges to allow easy replacement and to shut the gauges off when not in use, thus extending their life. Seal Water Seal water is usually supplied from the discharge of the volute case. If the seal water is obtained from some other source, a pressure gauge should be installed in the seal water line in order to assure that fow is in the correct direction, and backfow protec- tion should be provided with an air gap. Vertical Turbine Components Line Shaft and Submersible Vertical turbines, as discussed here, include line shaft and submersible turbines. Inlet Water enters the vertical turbine through the suction bell. It then passes into the pump bowl 28 . The bowl serves the same function as the volute case on an end suction centrifugal. This is where energy is transferred to the water by the impellers. Impellers Most line shaft and submersible turbines have more than one impeller. Each impeller and pump bowl is referred to as a pump stage. Adding stages increases the discharge pressure of the pump, but not its fow. Column Water passes out of the pump bowl assembly and into the column. In the center of the column is the pump shaft, which may be lubricated with water or oil. Discharge Head The large cast iron component at the top of the pump is the discharge head. It is here that the direction of fow is changed from vertical to horizontal. The discharge head also contains the stuffng box and the mechanical seal or packing. 28 Pump Bowl - The case that func- tions as a volute case on a mixed ow vertical turbine. 27 Concentric Reducer A device used to connect a large pipe to a smaller pipe so that the center lines of both pipes are aligned. 207 Chapter 6 Introduction to Pumping Systems Motor On top of the discharge head is the pump motor. The motor can be removed from the pump by removing a nut on the pump shaft located on the top of the motor. The mo- tor can then be lifted off the pump shaft for maintenance. HOLLOW SHAFT MOTOR STUFFING BOX DISCHARGE HEAD DRIVING SHAFT SUCTION BELL PUMP UNIT SCREEN IMPELLER BOWL
Lineshaft turbine Vertical Turbine Special Piping Reversal of Flow When a vertical turbine is shut down, water runs back down the column or drop line. Line shaft turbines have special non-reversing ratchets built into the motor to prevent the pump from spinning backwards. Small submersible turbines are installed with a check valve at the top of the pump to prevent water from running backwards through the pump. Air Control To prevent contamination from entering the discharge line through the stuffng box, an air valve is placed on the discharge line. This valve allows air in and, when the pump starts, allows the air out. Flow Pressure Control Like the end suction centrifugal, fow and pressure control with vertical turbines is accomplished using wide body globe valves and butterfy valves. 208 Introduction to Pumping Systems Chapter 6 CONTROL VALVE AIR RELEASE Submersible Turbine Components Inlet The water inlet into a submersible turbine is between the pump and the motor. Water moves through pump bowls that are, in most cases, identical to those of the line shaft turbine. Drop Pipe Water moves up from the submersible turbine, through the drop pipe, and out the discharge head. INLET SCREEN ELECTRICAL CONNECTION DROP PIPE ELECTRIC MOTOR BOWLS & IMPELLERS INLET SCREEN CHECK VALVE Sanitary Seal Vent Drop Discharge Head 209 Chapter 6 Introduction to Pumping Systems Cavitation Cavitation is the condition where vapor bubbles are formed in a fowing liquid when the pressure of the liquid falls below its vapor pressure. Once the bubbles reach an area where the pressure increases above vapor pressure, the bubbles collapse thereby creating small areas of high temperature and emitting shock waves. Cavitation in a centrifugal pump occurs when the inlet pressure falls below the design inlet pressure or when the pump is operating at a fow rate higher than the design fow rate. When the inlet pressure in the fowing liquid falls below its vapor pressure, bubbles begin to form in the eye of the impeller. Once the bubbles move to an area where the pressure of the liquid increases to above its vapor pressure, the bubbles collapse thereby emitting a shock wave. These shock waves can pit the surface of the impeller and shorten its service life. The collapse of the bubbles also emits a ping- ing or crackling noise that can alert the operator that cavitation is occurring. Cavitation is undesirable because it can damage the impeller, cause noise and vibra- tion, and decrease pump effciency. Major Components While there are several different types of positive displacement pumps available, this section is limited to those commonly used in small water systems. Never pump against a closed discharge or suction valve when using any positive dis- placement pump. This could result in severe damage to personnel and/or equipment. Diaphragm Pumps The diaphragm pump is composed of the following: A chamber used to pump the fuid A diaphragm operated by either electric or mechanical means Two valve assemblies: a suction valve assembly and a discharge valve as- sembly When the diaphragm is pulled back, a vacuum is created in the chamber in front of the diaphragm. This vacuum causes the discharge valve to be forced closed against its seat. The vacuum allows atmospheric pressure to push fuid up against the outside of the suction valve, opening the valve and flling the chamber. When pressure is returned to the diaphragm, forcing it toward the front of the chamber, the in- creased pressure causes the suction valve to be forced closed and the discharge valve to be forced open. The fuid is pushed out of the chamber, and the pumping cycle starts over. Positive Displacement Pumps VALVE OPEN VALVE CLOSED VALVE CLOSED VALVE OPEN FLEXIBLE DIAPHRAGM PISTON BALL CHECK VALVE ROTATING CAM SUCTION PHASE DISCHARGE PHASE 210 Introduction to Pumping Systems Chapter 6 Piping System The piping system for diaphragm pumps used to pump chemicals is relatively simple. There are a foot valve and screen on the suction line and a check valve on the end of the discharge line. The foot valve prevents loss of prime. The discharge check valve prevents the system water from fowing back into the chemical feed tank. CHEMICAL FEED PUMP CHECK VALVE 4-IN-1 VALVE DISCHARGE LINE WEIGHT CHLORINE SOLUTION STRAINER FOOT VALVE Piping System Peristaltic Pumps A peristaltic pump is a type of positive displacement pump used for pumping a vari- ety of fuids, such as chemicals and sludges. The fuid is contained within a fexible tube ftted inside a circular pump casing. A rotor with a number of rollers (or shoes) is attached to a rotating arm that compresses the fexible tube. As the rotor turns, the part of tube under compression closes, thus forcing the fuid to be pumped through the tube. This works much like squeezing toothpaste out of a tube. Since they have no moving parts in contact with the fuid, peristaltic pumps are inex- pensive to manufacture. Their lack of valves, seals, and glands makes them compara- tively inexpensive to maintain, and the use of a hose or tube makes for a relatively low-cost maintenance item compared to other pump types. 211 Chapter 6 Introduction to Pumping Systems It is important to select tubing with appropriate chemical resistance towards the liquid being pumped. Types of tubing commonly used in peristaltic pumps include polyvinyl chloride (PVC), silicone rubber, and fuoropolymer. Trade names include Tygon and Viton. Progressive Cavity Pumps A progressive cavity pump moves fuid by means of a rotary screw or rotor turn- ing within a stationary stator. The fow rate is proportional to the rotation rate of the pump. Progressive cavity pumps are designed to transfer fuid or fuids with suspend- ed solids. They are frequently used to pump sludge, but can be used to meter large volumes of chemicals in a precise manner. Operation As the rotor turns, humps built into the rotor move within cavities in a synthetic rubber stator. This action squeezes material out of the end of the pump in much the same way as with peristaltic pumps. These pumps should always run with a fuid inside to lubricate the pump. A progressive cavity pump should never be operated against a closed valve. This brief discussion on hydraulics is intended as a background necessary to under- stand the pumping and piping systems at a beginning level. The lesson is divided into two parts; 1) basic hydraulic terms and concepts and 2) pumping hydraulics. Weight-Volume Relationship Weight per Cubic Foot Cubic feet and gallons are both used to describe a volume of water. There is a defned relationship between these two methods of measurement. The specifc weight of water is defned relative to a cubic foot. One cubic foot of water weighs 62.4 pounds. This relationship is true only at a temperature of 4C and at a pressure 29 of one atmosphere (called standard temperature and pressure). However, the weight varies so little that for practical purposes we use this weight from a temperature of 0C to 100C. 1 ft 3 H 2 O= 62.4 lbs Volume per Cubic Foot At standard temperature and pressure, one cubic foot of water contains 7.48 gallons. With these two relationships we can determine the weight of one gallon of water. This is accomplished by dividing the weight (62.4 lbs) by the volume in gallons (7.48 gallons per cubic foot). 1ft. 1ft. 1ft. 1 Cubic Foot 7.48 Gallons 62.4 Pounds wt of gal of water = 62.4 lbs = 8.34 lbs/gal 7.48 gal 29 Pressure The force exerted on a unit area. Pressure = Weight x Height. In water, it is usually measured in psi (pounds per square inch). One foot of water exerts a pressure of 0.433 pounds per square inch. Basic Hydraulic Terms and Concepts 212 Introduction to Pumping Systems Chapter 6 Summary 1 ft 3 H 2 O = 7.48 gallons 1 gallon H 2 O = 8.34 pounds Conversion ft 3 to gallons With this information we can convert cubic feet to gallons by simply multiplying the number of cubic feet by 7.48 gal/ft 3 . Example Conversion ft 3 to gallons Find the number of gallons in a reservoir that has a volume of 668.5 ft 3 . 668.5 ft 3 x 7.48 gal/ft 3 = 5,000 gallons Force and Pressure Force In the English system force 30 and weight are often used in the same way. The weight of the cubic foot of water is 62.4 pounds. The force exerted on the bottom of the one foot cube is 62.4 pounds. If we have two cubes stacked on top of one another, the force on the bottom will be 124.8 pounds. Pressure Pressure is a force per unit of area, pounds per square inch or pounds per square foot are common expressions of pressure. The pressure on the bottom of our cube is 62.4 pounds per square foot. It is normal to express pressure in pounds per square inch (psi). This can be accomplished by determining the weight of one square inch of our cube one foot high. Since the cube is 12 inches on each side, the number of square inches on the bottom surface of the cube is 12 x 12 = 144 in 2 . Now by dividing the weight by the number of square inches we can determine the weight on each square inch. 12" 12" 12" 62.4 lbs. 1" 1" 12" psi = 62.4 lbs/ft = 0.433 psi/ft 144 in 2
This is the weight of a column of water one inch square and one foot tall. If the col- umn of water were two feet tall and the pressure would be 2 ft x 0.433 psi/ft = 0.866 psi. 1 ft of water = 0.433 psi Conversion feet to psi With the above information we can convert feet of head 31 to psi by multiplying the feet of head times 0.433 psi/ft. 31 Head The measure of the pressure of water expressed as height of water in feet: 1 psi = 2.31 feet of head. 30 Force Inuence (as a push or pull) that causes motion. Physics - The mass of an object times its acceleration: F = ma. 213 Chapter 6 Introduction to Pumping Systems Example Conversion feet to psi A reservoir is 40 feet tall. Find the pressure at the bottom of the reservoir. 40 ft x 0.433 psi/ft = 17.3 psi Conversion of psi to feet The conversion of psi to feet is simply made by dividing the psi by 0.433 psi/ft. Example Conversion of psi to feet Find the height of water in a tank if the pressure at the bottom of the tank is 12 psi. 12 psi 0.433 psi/ft = 27.7 ft Pressure and Head Pressure is directly related to the height of a column of fuid. This height is called head or feet of head. From the discussion above we see there is a direct relationship between feet of head and pressure. The relationship is that for every one foot of head there is a pressure of 0.433 psi. Pressure Relative to Container Size The pressure at the bottom of a container is affected only by the height of water in the container and not by the shape of the container. In the drawing below there are four containers all of different shapes and sizes. The pressure at the bottom of each is the same. 50 ft. Pressure and Volume The pressure exerted at the bottom of a tank is relative only to the head on the tank and not the volume of water in the tank. For example, below are two tanks each con- taining 5000 gallons. The pressure at the bottom of each is 22 psi. If half of the water were drained from the tanks the pressure at the bottom of the elevated tank would be 17.3 psi while the pressure at the bottom of the standpipe would be 11 psi. 214 Introduction to Pumping Systems Chapter 6 50 ft. 40 ft. 25 ft. 22 psi 22 psi 17.3 psi 11 psi Velocity and Flow Velocity Velocity is the speed that the water is moving along a pipe or through a basin. Veloc- ity is usually expressed in feet per second, ft/sec. Flow Flow is commonly expressed in gallons per minute (gpm) and/or cubic feet per second (cfs). There is a relationship between gallons per minute and cubic feet per second. One cubic foot per second is equal to 448.8 gallons per minute. 1 cfs = 448.8 gpm Flow Equation The basic equation for determining fow is as follows: Q = V x A Where: Q = cfs (ft 3 /sec) V = ft/sec A = ft 2 Static and Dynamic Conditions Static Pressure The pressure measured when there is no water moving in a line or the pump is not running is called static 32 pressure. This is the pressure represented by the gauges on the tanks in the discussion above. Dynamic Pressure When water is allowed to run through a pipe and the pressure (called pressure head) measured at various points along the way we fnd that the pressure de- creases the further we are from the sources. 32 Static A non-moving condition. Pressure Head 215 Chapter 6 Introduction to Pumping Systems Headloss The reason for this reduction in pressure is a phenomenon called headloss. Headloss is the loss of energy (pressure) due to friction. The energy is lost as heat. Explanation When we hear that the headloss in a certain pipe is 25 feet, that means the amount of energy required to overcome the friction in the pipe is equivalent to the amount of energy that would be required to lift this amount of water straight in the air 25 feet. Factors Contributing to Headloss In a pipe, the factors that contribute to headloss include the following: Roughness of pipe Length of pipe Diameter of pipe Velocity of water Comparison of Factors In general, if the roughness of a pipe were doubled the headloss would double. If the length of the pipe were doubled the headloss would double. If the diameter of a pipe were doubled the headloss would be cut in half and if the velocity of the water in a pipe were doubled the headloss would be increased by about four times. It should be apparent that velocity, more than any other single factor, affects headloss. To double the velocity we would have to double the fow in the line. Example Headloss 500 feet of four inch line with a fow of 110 gpm has a headloss of 7.5 feet. At a fow of 220 gpm, the headloss jumps to 26 feet or an increase of 3.5 times. Fittings and Headloss Each type of ftting has a specifc headloss depending upon the velocity of water through the ftting. For instance the headloss though a check valve is two and one quarter times greater than through a ninety degree elbow and ten times greater than the headloss through an open gate valve. Basic Terms Static Head Static head is the distance between the suction and discharge water levels when the pump is shut off. Static head conditions are often indicated with the letter Z. Suction Lift Suction lift is the distance between the suction water level and the center of the pump impeller. This term is only used when the pump is in a suction lift condition. A pump is said to be in a suction lift condition any time the eye (center) of the impeller is above the water being pumped. Suction Head Suction head is the distance between the suction water level and the center of the pump impeller when the pump is in a suction head condition. A pump is said to be in Pumping Hydraulics 216 Introduction to Pumping Systems Chapter 6 a suction head condition any time the eye (center) of the impeller is below the water level being pumped. Velocity Head Velocity head 33 is the amount of energy required by the pump and motor to overcome inertia 34 and bring the water up to speed. Velocity head is often shown mathemati- cally as V 2 /2g. (g is the acceleration due to gravity 32.2 ft/sec 2 ). Velocity Head Total Energy Total Dynamic Head Total dynamic head 35 (TDH) is a theoretical distance. It is the static head, velocity head and headloss required to get the water from one point to another. Z = 80 ft. H = 19 ft. L V /2g = 1ft 2 TDH = 100 ft. Velocity Head Suction Lift Static Head Headloss T o t a l
D y n a m i c
H e a d Components of total dynamic head Horsepower Horsepower 36 is a measurement of the amount of energy required to do work. Mo- tors are rated in horsepower. The horsepower of an electric motor is called brake horsepower. The horsepower requirements of a pump are dependent on the fow and the total dynamic head. 36 Horsepower A measurement of work, 33,000 foot pounds per minute of work is 1 horsepower. 33 Velocity Head The amount of energy required to bring a uid from standstill to its velocity. For a given quantity of ow, the velocity head will vary indirectly with the pipe diameter. 34 Inertia The tendency of matter to remain at rest or in motion 35 Total Dynamic Head (TDH) The total energy needed to move water from the center line of a pump (eye of the rst impeller of a lineshaft turbine) to some given elevation or to develop some given pressure. This includes the static head, velocity head and the headloss due to friction. 217 Chapter 6 Introduction to Pumping Systems Horsepower and Amperage The horsepower output of an electric motor is directly refected to the amperage 37
that the motor draws. Any increase in horsepower requirements will give a corre- sponding increase in amperage. Pump Response For centrifugal pumps, as the total dynamic head is increased the pump will pump less water and will require less horsepower. Identifcation Identify the components indicated in the drawing below. ______ A. Volute case ______ B. Mechanical seal ______ C. Impeller ______ D. Stuffng box ______ E. Shaft sleeve 22 21 19 20 17 15 31 24 35 36 16 14 13 18 28 1 27 4 5 2 3 23 30 24 32 19 33 34 29
37 Amperage The measurement of electron ow. 218 Introduction to Pumping Systems Chapter 6 Review 1. One cubic foot of water weighs__________ pounds, and contains ___________ gal- lons. 1. One gallon of water weighs _____________lbs. 1. Looking at the two reservoirs below, will the pressure at the bottom be: A. The same B. Greater in the tank on the left C. Greater in the tank on the right 50 ft. 1. A tank contains 500 cubic feet. This converts to how many gallons? 1. A fow of one cubic foot per second is equivalent to __________ gpm. 1. Headloss is the result of _____________. The energy given off as a result of headloss is given off as _____________. 1. What term is used to describe the difference between the level of water in a well and the level of water in the reservoir when the pump is shut down? ____________________ 1. What units are used to measure the energy required to do the work of pumping water? ________________________ 1. It is 60 feet in elevation from the level of water at the top of the reservoir to the pump house. What is the static water pressure at the pump house? 219 Chapter 6 Introduction to Pumping Systems Identifcation Identify the three pumps below by confguration. 1. 2. 1. ____________________________________ 2. ____________________________________ 3. ____________________________________ 3. Identify the components indicated in the drawing below. A. __________________ B. __________________ C. __________________ D. __________________ E. __________________ F. __________________ F E C B C A G E D F E C B C A G E D 220 Introduction to Pumping Systems Chapter 6 1. Which type of pump is frequently used to pump water from wells? A. Progressive cavity pumps B. Submersible turbine pumps C. Reciprocating pumps D. Circulating pumps 2. What is the purpose of pump mechanical seals? A. Keep leakage off slippery foors B. Prevent leakage between the pump casing and shaft C. Provide an effective backfow prevention device D. Seal water to maintain pump prime 3. What is the primary purpose of priming a pump? A. Ensure the pump operates freely B. Fill the volute with water C. Prevent backfow D. Start the seal water fow 4. The component of a centrifugal pump sometimes installed on the end of the suc- tion pipe is called the: A. Volute B. Foot valve C. Impeller D. Packing 5. Positive displacement pumps should never be operated: A. Backward B. With a closed discharge or suction valve C. Without supervision D. Without a concentric reducer 6. Pumps that are used to feed chemicals should: A. Never be run in auto B. Never be run dry C. Always be controlled by a fow switch D. Always be controlled by a level sensor 7. Packing should be adjusted when: A. Excessive leakage from the discharge pipe is noticed B. Excessive leakage from the stuffng box is noticed C. Pump prime is lost D. The pump is shut down Introduction to Pumping Systems Quiz 221 Chapter 6 Introduction to Pumping Systems 8. Closed impellers should be used for: A. When the pump is used to pump sludge B. When the pump is used to circulate glycol C. When the pump is used to pump chemicals D. When the pump is used to boost pressure 9. Check valves are used to: A. Control leakage from the stuffng box B. Ensure pump is isolated from the system for maintenance C. Prevent water from fowing in reverse D. Fill water storage tanks 10. Pump couplings are used to: A. Ensure pump is properly connected to discharge piping B. Connect the motor to the pump C. Provide cooling water for the stuffng box D. Keep the pump primed 11. One cubic foot of water weighs ______________ pounds and contains ______________ gallons. A. 8.34 lbs, 7.48 gallons B. 7.48 lbs, 62.4 gallons C. 11.3 lbs, 5 gallons D. 62.4 lbs, 7.48 gallons 12. One gallon of water weighs ______________ lbs. A. 3.42 lbs B. 7.48 lbs C. 8.34 lbs D. 4.56 lbs 13. A tank contains 500 cubic feet. This converts to how many gallons? A. 3740 gallons B. 66.8 gallons C. 4170 gallons D. 59.9 gallons 14. A fow of one cubic foot per second is equivalent to ______________ gpm. A. 62.4 B. 179.5 C. 7.48 D. 448.8 222 Introduction to Pumping Systems Chapter 6 15. Headloss is the result of ______________. The energy given off as a result of headloss is given off as ______________. A. Pressure, head B. Friction, heat C. Flow, electricity D. Weight, noise 16. What term is used to describe the difference between the level of water in a well and the level of water in the reservoir when the pump is shut down? A. Drawdown B. Static head C. Well yield D. Dynamic head 17. Describe Total Dynamic Head (TDH). A. Total pressure a pump will pump B. Composed of headloss, velocity head, and static head. C. Amount of pressure in a well D. A toilet on a submarine 18. What is the difference between suction lift and suction head? A. Total dynamic head in the pumping system B. Static head between the pump suction and discharge. C. Relationship between the eye of the impeller of the pump and the surface water from which the pump is pumping. D. There is no difference 19. What units are used to measure the energy required to do the work of pumping water? A. Microns B. Horsepower C. Foot-pounds D. Gallons per minute 20. It is 60 feet in elevation from the level of water at the top of the reservoir to the pump house. What is the static water pressure at the pump house? A. 500.4 psi B. 25.98 psi C. 138.6 psi D. 448.8 psi